Mitsubishi Hitachi Power Systems
Integrated Solutions for flexible operation of fossil fuel power plants
Workshop on the role of the renewable and hydrocarbon nexus in accelerating the energy transitionIEA Gas & Oil Technology collaboration program11&12 October 2018 Venue: The Hotel, Boulevard de Waterloo 38, Brussels
Dr.-Ing. Christian Bergins
Strategic Marketing
Manager
Business Development
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Contents
1. Introduction: MHPS & MHI
2. Flexible Generation
3. Fuel Flexibility
2
4. Storage integrated in Power Plants, Developments
5. Summary
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3
MHPS Overview
Mitsubishi Hitachi Power Systems
Mitsubishi Hitachi Power Systems Europe
65% 35%
100%
Start of joint venture: 1 February 2014
HQ Location: Yokohama, Japan
Number of MHPS Group companies: 65
Total workforce: approx. 19,500
Capital: ¥100b / $892m (USD/JPY: 112)
Mitsubishi Hitachi Power Systems Europe
HQ Location London
Workforce 1,200
Market Region:
Europe, Middle East, Africa (EMEA)
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4
Product Line Up
Geothermal Power Plants
GeneratorsGas Turbines
Peripheral EquipmentCoal Power Plants
Neues Foto Rotterdam
Combined Cycle Gas Turbine Plants Boilers
Steam Turbines
Environmental Plants SCR (DeNOX) Systems / Flue Gas Desulfurization
Integrated Coal Gasification Combined Cycle (IGCC)
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Where is MHPS in the MHI World?
5
{Industry & Infrastructure Domain}
{Power Systems Domain} {Aircraft, Defense & Space Domain}
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New organisation of MHI, MHPS for Energy Solutions:Extended Portfolio of Power Equipment and Services including ESCO
6
GTCC
★: Renewable Energy
Nuclear PowerBoilerIGCCCentralisedPower Generation
Hydro
DistributedPower Generation
Wind Turbine (Offshore)
Geothermal
Gas Engine
ORC
Biomass
ESS(Battery)
SOFC
EMS
Gas EngineAero-GT HD-GT
0.5 10 5 10 50 100 1000500
Purpose
Utility
IndustryMunicipality
★
★
★
★
★
Diesel Engine
Output [MW]
ESS(LAES,CAES)
★: Large Scale Carbon Capture commercially available
★
★ ESS (PtF)
★: Energy Storage
★
★
★
★
EMS : Energy Management System
ESS : Energy Storage System GTCC : Gas Turbine Combined
System HD-GT : Heavy Duty Gas Turbine
IGCC : Integrated Coal Gasification System
ORC : Organic Rankine Cycle SOFC : Solid Oxide Fuel Cell
LAES : Liquid Air Energy StorageCAES : Compressed Air Energy
StoragePtF : Power to Fuel
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Flexible Power Generation
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The future Technology Responses to High RES grid
8
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Operational flexibilityExamples for flexible, coal fired power plants
First measure:Utilizing the inherent
flexibility characteristics in old
and new hard coal power plants
60
GW
50
40
30
20
10
Source: VGB PowerTech 11/2012 & own data
0%
20%
40%
60%
80%
100%
Mo Tu We Th Fr Sa Su
150MW Hard Coal,Sept. 2010
0:00 6:00 12:00 18:00 0:00
Time
700 MW Hard Coal,2012
Load
9
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10
M501GAC-fAST CC PLANTOver 8OOMW in 30 Minutes
Standard lndustry Design Practices Applied
HRSG: Drum Type design, 3P Reheat with duct firing
30 year design life under cycling duty
Designed to NFPA 85-2011 for avoiding purge at start-up
Stack damper for Heat Retention
SCR and CO catalysts designed for fast response
Single case steam turbine, with welded HP/IP rotor to
enable faster ST ramping
Operational flexibilityFast Start-Up CCGT
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11
Operational flexibilityTypical Plant Start-Up Comparison
Hot Start
Reduced Start-up: Time, Fuel & Emissions
Plant Start Up improvements translate to simplified air permits and better overall plant economics
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PWPS Gas Turbinesmobile solutions to ensure security of supply
High Efficiency to save Oil & Gas.
Water Free to meet requirements in Middle East Area.
Maximum Factory-assembled module to reduce Site Erection Cost and Time.
Fast start to full load within 5 minutes.
Off site maintenance to reduce Shutdown period.
FT4000 SWIFTPAC FT8 MOBILEPAC
World Largest Aero-Derivative
GT of 140MW Twin pack.
Dual fuel capability.
Modular package for easy
installation.
One day installation (Site ready)
None Concrete Foundation
Dual fuel / dual frequency capability.
Two-trailer design for Cost –effective
of transportation and site works.
12
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38m
11
m ControlTrailer
GT/GENTrailer
Exhaust StackInlet
Filter
ControlTrailer
GT/GENTrailer
General Arrangement of FT8 MOBILEPAK
13
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Fuel Flexibility
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Fuel flexibilityBiomass conversion of steam generator
15
Biomass related systems Coal / biomass bunker Coal / biomass feeder Coal / biomass mill Pulverized fuel lines Burners De-asher Air / flue gas systems
References:2002: P.S. Amer 9 in Geertruidenberg, Netherlands, 1 Mill converted2014: P.S. Stustrupvaerket (SSV), Denmark, 930 MWth, 100% conversion (fuel switch coal-biomass-coal possible during operation)2014: P.S. Avedøreværket (AVV1), Denmark, 611 MWth, 100% conversion, burner replacement, mill refurbishment2015: P.S. Atikokan in Ontario, Canada, one burner level, one mil refurbished2010-2014: P.S. Drax Unit 1-3, United Kingdom, 3x660MWel 100% conversion (biomass burners)
Retrofit experience for existing plantssince 2002
Burner
Coal Bunker
Coal Feeder
Boiler
De-Asher PA Fan
FD Fan
Safety Damper
Air Heater
Stack
ID Fan
ESP FGD
Sealing Air Fan
MPS® Mill
Furnace
Biomass /
Biomass /
n x
PAC
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“on-the-fly” Fuel Switch from Biomass to Coal
16
Coal & “coarse grained hard pine pellet”
(Grenå)
Mass flow coal 0 → 6.4 kg/s
Mass flow biomass 9.85 → 0 kg/s
Primary Air flow 14.2 Nm3/s
PA Temperature 145 → 309°C
Differential pressure 40 → 48 mbar
Classifier temperature 66 → 95 °C
Mill Motor in 67 → 70 → 60%
Classifier speed 20 → 90 rpm
- Uninterrupted firing
- No supporting fireScreen shot of mill 40 operation charts at
switch from wood pellet to coal operation
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“on-the-fly” Fuel Switch from Coal to Biomass
17
Coal & “coarse grained hard pine pellet”
(Grenå)
Mass flow coal 7.34 → 0 kg/s
Mass flow biomass 0 → 9,85 kg/s
Primary Air flow 14,2 Nm3/s
PA Temperature 300 → 140°C
Differential pressure 61 → 54 mbar
Classifier temperature 85 → 62 °C
Mill Motor in 70 → 88 → 75%
Classifier speed 90 → 20 rpm
Screen shot of mill 40 operation charts at switch from coal to wood pellet operation
- Uninterrupted firing
- No supporting fire
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Fuel flexibility Conversion of Coal Fired Power Plant to CCGT
18
Owner:HKW-Wuerzburg,
Wuerzburg, Germany
Plant: Combined Cycle Power Plant II
(former coal boiler)
Fuel: Natural gas(GT + duct burner)
GT capacity: 25 MWel
Unit capacity: 55 MWth
Boiler capacity: 95 t/h
SH outlet press: 72 bar
SH outlet temp.: 515 ºC
Fuel switch coal to natural gas, old boiler fully refurbished GT and duct burners added
Heat and Power Plant Wuerzburg, Germany
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Fuel flexibility Conversion of Coal Fired Power Plant to CCGT
19
Result of conversion: High operational flexibility, high
efficiency50 000 t/a less CO2 with the same
energy generation
Before Rehabilitation (Plant view in 1987)
After Rehabilitation (2016)
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Fuel flexibility Repowering coal power plants with gas turbines
20
330 MWel Coal fired P.S.
GT 60 MWel
Power increase by steam & heat recovery 38MWel
Total el. power Increase: 98 MWel
Fuel utilisation: up to 80 % (CHP)
G
G
Existing Power Plant
Repowering
Gas turbine(s) HP recovery
preheater
LP recovery
preheater
Lignite power plant
Matra, Hungary
(Feedwater pre-heating)
G
G
Existing Power Plant
Repowering
Gas turbine(s) HP recovery
preheater
LP recovery
preheater
IP Superheater
IP Evaporator
IP Economizer
Co-generation power station
„Altbach Deizisau“
(Feedwater pre-heating & IP steam)
2 x 212 MWel Lignite P.S.
2 x Hitachi H-25AX – 30 MWel
Power increase by preheaters 20 MWel
Total el. power Increase: 100 MWel
Fuel utilisation: 90.3 % (CHP)
More Efficiency, More Power, High load flexibility, Lower specific EmissionsQuicker reserve power than CCGT (ST already in operation)
Cheaper than separate, new CCGT and similar efficiency regarding NG
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Conversion from coal to highly efficient CHP CCGT
Oeresundsverket, Malmö, Sweden
447 MW Combined Cycle Power Plant
Build in existing building, replacing coal boiler
Gas Turbine:
1 x GE 9FB – 293 MW
Heat Recovery Steam Generator:
1 x Triple Pressure Boiler
HP: 309 t/h, 140 bar, 567 ºC
Steam Turbine:
1 x Extraction/Condensing Type
161 MWel
Up to 250 MWth heat supply
Up to 90% fuel efficiency
Fuel:
Natural Gas
Year of Commissioning : 2009
Even when all other conversion ideas are uneconomic:
Existing assets and infrastructure still can be used for modern heat and/or
power generation
21
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Power Plant Integrated Storage
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Liquid Air Energy Storage (LAES) Time-shift of electric power / energy storage
GLiquid
air storage
M
Coldstorage
LAES storage (liquid air production & waste heat recovery in LP PH)
LAES energy release (liquid air evaporation and heating by bleed steam, air expansion)
HP pre-heating LP pre-
heating
0,5
0,4
0,3
0,2
0,10 200 400 600 800 900
PNet [MW]
𝛈𝐍𝐞𝐭[−]
reduced
minimnum
load by
process
integrated
storage
High
additional
power by
small fuel
demand
increase
time shift of
electric power
combined operation
(with LAES)
steam cycle only
Effective reduction of minimum load by- Energy storage (increased self
consumption)- Reduction of LP bleed steam (avoiding
ventilation)
Increase of maximum power- by utilizing stored energy- with minimum OPEX compared to GT
topping cycle
Efficient combination possible with CHP plants and heat storage
23
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CCU/PtF integrated in Biomass CHP Plants or Industry
24
Transmission
systemHeat
consumers
Heat storage
Electric Power Pel
Thermal Power Qth
Industry
(heat consumer)
H2
water electrolysis
CO2
Fuel
synthesis
water
gas
(CO2 lean)
gas
(CO2
rich)
“low carbon” O2
Post combustion
CO2 capture
815MWth
344MWel 158MWth200kt/year
Significant amounts of
synthetic biofuels are
produced for additional CO2
reduction in the transport
sector
CCU can be sized larger to
absorb excess intermittent
RES electricity and re-use
more CO2
Fuel
CCU: Carbon Capture and UtilisationPtF: Power to Fuel
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Developments towards zero carbon energy
25
Solid Oxide Fuel Cells (SOFC)
Effectively utilizing high exhaust temperature at 1,000°C
High durability, solid-state material
Fuel flexibility using natural gas, oil or coal
First demonstrators in operation
Power-to-Fuel (PtF) & Carbon Capture and Utilisation
(CCU)
Methanol synthesis from CO2 and hydrogen
The processing of methanol into various (drop-in) fuels
Small demonstrators under construction
Today, small scale gas turbines (e.g. H25) are ready for
deployment to operate on hydrogen or hydrogen rich gases, COG
and refinery gas references exist
MHPS is involved in Hydrogen Conversion Project at Natural Gas
GTCC Power Plant in the Netherlands (for 440MW GTCC by 2023)
Hydrogen Combustion in Gas Turbines
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Summary
26
Today many power plants need to operate in a wide load
range with fast ramping and frequent starts while maintaining
equipment durability, environmental compliance, and low cost of
electricity.
Operational Flexibility and Fuel Flexibility is key to ensure
security of supply, economic operation as well as CO2 emission
reduction using existing assets or designing new equipment.
MHPS has proven fuel switches for existing plants to natural
gas and biomass. Hydrogen as a fuel in gas turbines is possible
already today.
MHPS is working on different technologies for integrated
energy storage to serve the future requirements of energy
markets.
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Mitsubishi Hitachi Power Systems
27
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